1. Bachelor of Industrial Technology Management with Honours Introduction to Manufacturing Technology Semester I Session 2013/2014

2. Taiz University  What is manufacturing?  Historical development of manufacturing technology  Economic role of manufacturing  Manufacturing as a technical activity  Manufacturing organization and enterprise  Standard measurement and measurement inspection TOPIC OUTLINE

3. Taiz University 1.Able to describe what the manufacturing technology is and its role in a country economy 2.Able to explain the interconnected activities involved in product realization 3.Able to identify the use and method to take reading of basic measuring instruments LESSON OUTCOMES

4. Taiz University Literal: Manufacture = Manus (hand) + Factus (make)  Made by hand Technological:Application of physical and chemical processes to make parts or products, including assembly of products. Economical:Transformation of materials into items of greater value by means of processing and/or assembly operations. CIRP definition:Design + production + assembly (CIRP = International Academy for Production Eng.) What is manufacturing?

5. Taiz University Representation of ‘manufacturing’ in a technological way What is manufacturing?

6. Taiz University Representation of ‘manufacturing’ in a economical way What is manufacturing?

7. Taiz University Manufacturing is an important mean to create material wealth!!! One job in a manufacturing plant generates about four other jobs else!!! Question: How? Data from the USA: - Manufacturing : ~ 20% of the GNP - Agriculture, mining: < 5% of the GNP - Construction, public utilities : ~ 5% of the GNP - Service sector : ~ 70% of the GNP (GNP = Gross National Product) Question: What are the figures for MALAYSIA? Importance of Manufacturing

8. Taiz University Historical Perspective (1) In broad outlines: Man’s discovery and invention of materials and processes to make things, since 6000 years ago Principle of division of labour  Adam Smith (~1750) Industrial Revolution (1770 – 1850), steam engine, machine tools, machinery for textile industry Factory system, UK American system, interchangeable parts  Whitney (~1800), guns (muskets), USA Second Industrial revolution  mass production, scientific management, assembly lines, Ford (~1915), cars, USA

9. Taiz University Historical Perspective (2) Manufacturing materials and processes: Neolithic period (~8000 - 3000 B.C.) in Mesopotamia Mediterranean, Asia; hammering, gold Bronze age (3500 - 1500 B.C.), extracting copper from ores, casting, hammering. Iron age (since 1000 B.C.), heating, quenching Industrial Revolution (1770 - 1850), machining like boring, turning, drilling, milling, shaping. Assembly methods (since ancient cultures), ships, weapons, tools, farming equipment Fusion welding (around 1900) Rubber and polymer shaping, vulcanization (1939)

10. Taiz University Manufacturing industries - Primary industries: natural resources as mining, fishing, agriculture, petroleum - Secondary industries: automotive, computers, electronics - Tertiary industries (service): banking, tourism, education Manufactured products - Consumer goods: cars, TV’s, tires, tennis rackets - Capital goods: aircraft, machine tools, machinery - Discrete products: pumps, shavers, coffee makers - Continuous produced products: sheet-metal coils Industries and Products

11. Taiz University Product Example Electric shaver

12. Taiz University Production variety: low, medium, high soft, hard Production quantity: low (<100), medium (10 2 -10 4 ), high (>10 4 ) Production Quantity & Variety

13. Taiz University Technological Processing capability - Available processes and machines - Outsourcing of some operations (casting, heat treatment, etc.) Physical product limitations - Size, weight - Machine dimensions, handling Production capacity (Plant capacity) - Production quantity in a given time, output Manufacturing Capability

14. Taiz University Metals - Ferrous: Steel (iron-carbon, 0,02% - 2,11% C) Cast iron (iron + 2% - 4% C + silicon) - Nonferrous: copper, aluminium, nickel, alloys Ceramics: clay, silica, carbides (Al, Si), nitrides (Ti) Polymers - Thermoplastic polymers: PE, PP, PS, PVC - Thermosetting polymers: phenolics, epoxies - Elastomers: rubber, neoprene, silicone, PU Composites: more phases, particles/fibres + matrix glass reinforced plastic, Kevlar, WC in cobalt Materials in Manufacturing

15. Taiz University Venn diagram Materials in Manufacturing

16. Taiz University Master Engineering & Management Manufacturing processes Classification of Manufacturing Processes

17. Taiz University 1)Shaping operations - Solidification processes  casting of metals, moulding of plastics - Particulate processing  powder metallurgy - Deformation processes  forging, extrusion - Material removal processes  machining, non- traditional, grinding 2)Property enhancing processes - Heat treatments, sintering 3)Surface processing - Cleaning, coating, plating Processing Operations

18. Taiz University 1) Processing operations 2)Assembly operations - Permanent joining: welding, brazing, adhesives - Mechanical assembly: bolts, screws, rivets, etc. 3)Production machines and tooling - Machine tools: lathe, milling machine, etc. - Presses, forge hammers, rolling mills - Welding machines and equipment - General and special purpose equipment - Tooling Manufacturing Processes

19. Taiz University Consist of people, equipment and procedures Production facilities: factory, production equipment material handling equipment  Plant layout + Manufacturing systems  Influence of production quantity (low, medium, high) Manufacturing support systems - Manufacturing engineering  process planning - Production planning and control  logistics, ordering materials and parts, scheduling - Quality control Production Systems

20. Taiz University Low quantity production (1 – 100 units/year) - Job shop  maximum flexibility, fixed-position layout and often also process layout - Examples: aircraft, ships, heavy machinery Medium quantity production (10 2 – 10 4 units/year) - Batch production  process layout or cellular layout, usually make-to-stock - Examples: pumps, lathes, gear drives High quantity production (> 10.000 units/year) - Flow line production  product layout - Examples: cars, household appliances Influence of Production Quantity

21. Taiz University Master Engineering & Management Fixed-position layout Process layout Cellular layout Product layout Plant Layouts

22. Taiz University Function Shape Process Material Mutual Relationships

23. Taiz University Mechanical properties, e.g. tensile strength Physical properties, e.g. thermal expansion Dimensions, e.g. mm Tolerances: bilateral, unilateral tolerances limit dimensions Geometric attributes: angularity, circularity, concentricity, cylindricity, flatness, parallellism, perpendicularity, roundness, squareness and straightness Surface quality, e.g. roughness Product Attributes

24. Taiz University Aspects: Batch size: Single product, medium size or mass production Geometric requirements: Shape and tolerances Manufacturing phase: Primary or secondary Tools: General purpose or product specific Assembly:Pay attention to assembly aspects during process selection for part manu- facturing Minimize costs: Costs per product + Costs per batch + Once-only costs Manufacturing Process Selection

25. Taiz University Production System

26. Taiz University Product design: Selection of the product material and the manufacturing process is related to the product shape and product function. Production systems: Selection of a manufacturing process is related to the optimum batch size and has consequences for the plant layout. Management and cost accounting: If more manu- facturing scenarios are possible, the final choice will be made based on minimum costs. Total Quality Management: All decisions related to manufacturing are dealing with quality aspects. Interfaces with Other Courses